US11642748B2 - Machining program creation method, workpiece machining method, and machine tool control device - Google Patents

Machining program creation method, workpiece machining method, and machine tool control device Download PDF

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US11642748B2
US11642748B2 US17/758,508 US202117758508A US11642748B2 US 11642748 B2 US11642748 B2 US 11642748B2 US 202117758508 A US202117758508 A US 202117758508A US 11642748 B2 US11642748 B2 US 11642748B2
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machining
tool
convex
workpiece
pair
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US20230051567A1 (en
Inventor
Daisuke UENISHI
Tomohiro Oyamada
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Fanuc Corp
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Fanuc Corp
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Assigned to FANUC CORPORATION reassignment FANUC CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Oyamada, Tomohiro, UENISHI, DAISUKE
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B23Q15/12Adaptive control, i.e. adjusting itself to have a performance which is optimum according to a preassigned criterion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B23Q15/14Control or regulation of the orientation of the tool with respect to the work
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23CMILLING
    • B23C3/00Milling particular work; Special milling operations; Machines therefor
    • B23C3/16Working surfaces curved in two directions
    • B23C3/18Working surfaces curved in two directions for shaping screw-propellers, turbine blades, or impellers
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/18Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/4093Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine
    • G05B19/40931Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by part programming, e.g. entry of geometrical information as taken from a technical drawing, combining this with machining and material information to obtain control information, named part programme, for the NC machine concerning programming of geometry
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/35Nc in input of data, input till input file format
    • G05B2219/35086Machining feature extraction, geometry and machining parameters
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/50Machine tool, machine tool null till machine tool work handling
    • G05B2219/50353Tool, probe inclination, orientation to surface, posture, attitude

Definitions

  • the present invention relates to a machining program creation method, a workpiece machining method, and a machine tool control device.
  • a cutting machine having a rotation axis, such as a five-axis machining center, is used.
  • the blade component is in a thin plate shape, and one of front and back surfaces of the blade component is formed as a convex surface and the other surface is formed as a concave surface.
  • machining of the blade component by the cutting machine rough machining with a miller, semi-finishing with a radius end mill, and finishing with a ball end mill are mainly employed.
  • high-efficiency removal machining for carving the blade component from a workpiece all at once by means of, e.g., a tapered ball end mill or a ball end mill is employed. Removal machining is performed while a tool is moving relative to the workpiece (see, e.g., Patent Document 1).
  • a machining program for such removal machining is created targeted for a solid body of the blade component by means of a surface of the solid body.
  • Patent Document 1 Japanese Unexamined Patent Application, Publication No. 2003-165012
  • FIG. 12 shows the blade component in a section perpendicular to a longitudinal axis direction (a direction perpendicular to the plane of paper of FIG. 11 ).
  • the section of the blade component 1 includes four curves (arcs or spline curves) of a convex surface 11 a , a concave surface 11 b , an edge portion 1 a (a trailing edge), and an edge portion 1 b (a leading edge).
  • the concave surface 11 b is formed such that the curvature thereof is inverted from those of the convex surface 11 a and the edge portions 1 a , 1 b.
  • a tool axis direction Ta is set to the direction of normal to these four curves.
  • a curvature direction of the concave surface 11 b is inverted when the blade component 1 rotates about the longitudinal axis direction relative to the tool T, and for this reason, the machining program has such a program configuration that the direction of operation of a rotation axis rotating the blade component 1 in a machine tool is reversed upon removal machining.
  • a machining program which defines, as shown in FIG. 13 , a direction about the longitudinal axis 12 of the blade component 1 as the tool axis direction Ta to reduce reversal of the direction of operation of the rotation axis without using the surface obtained from the solid body targeted for machining for definition of the tool posture.
  • machining of the blade component 1 in the thin plate shape is such machining that a tip end of the tool T at a circumferential speed of zero is used to poke the workpiece from the tool axis direction Ta, and therefore, leads to a machined surface defect due to vibration of the tool T and insufficient chip discharging and is not practical.
  • a machining program creation method, a workpiece machining method, and a machine tool control device configured so that a high-quality machined surface can be obtained at high speed without the need for reversing the direction of operation of a rotation axis in high-efficiency blade component machining have been demanded.
  • a machining program creation method is a machining program creation method for machining a component having a convex surface and a concave surface with respect to a pair of edge portions from a workpiece by removal machining, the method including setting, for the concave surface, a virtual convex curve whose curvature is not inverted from that of the convex surface with reference to tangents to curves of the pair of edge portions, creating a tool posture defining drive surface by means of the virtual convex curve, a convex curve set for the convex surface, and convex curves set for the pair of edge portions such that the curvature of the tool posture defining drive surface is not inverted, and creating a machining program for setting a tool axis direction upon removal machining with reference to the direction of normal to the tool posture defining drive surface.
  • a workpiece machining method is a workpiece machining method for machining a component having a convex surface and a concave surface with respect to a pair of edge portions from a workpiece by removal machining, the method including setting, for the concave surface, a virtual convex curve whose curvature is not inverted from that of the convex surface with reference to tangents to curves of the pair of edge portions, creating a tool posture defining drive surface by means of the virtual convex curve, a convex curve set for the convex surface, and convex curves set for the pair of edge portions such that the curvature of the tool posture defining drive surface is not inverted, setting a tool axis direction upon removal machining with reference to the direction of normal to the tool posture defining drive surface, and determining a tool posture based on the tool axis direction to machine the component from the workpiece by removal machining.
  • a machine tool control device is a control device of a machine tool for machining a component having a convex surface and a concave surface with respect to a pair of edge portions from a workpiece by removal machining, the control device including a tool posture defining drive surface creation unit that sets, for the concave surface, a virtual convex curve whose curvature is not inverted from that of the convex surface with reference to tangents to curves of the pair of edge portions and creates a tool posture defining drive surface by means of the virtual convex curve, a convex curve set for the convex surface, and convex curves set for the pair of edge portions such that the curvature of the tool posture defining drive surface is not inverted, and a machining program creation unit that creates a machining program for setting a tool axis direction upon removal machining with reference to the direction of normal to the tool posture defining drive surface.
  • the machining program creation method, the workpiece machining method, and the machine tool control device configured so that a high-quality machined surface can be obtained at high speed without the need for reversing the direction of operation of the rotation axis in high-efficiency blade component machining can be provided.
  • FIG. 1 is a perspective view showing a blade component machined from a workpiece by removal machining
  • FIG. 2 is a perspective view showing one embodiment of a machine tool
  • FIG. 3 is a perspective view showing, in closeup, a state in which a blade surface of the blade component is machined by removal machining by the machine tool shown in FIG. 2 ;
  • FIG. 4 is a block diagram showing the configuration of a control device of the machine tool
  • FIG. 5 is a view for describing one embodiment of the method for creating a tool posture defining drive surface for the blade component
  • FIG. 6 is a view showing one embodiment of the tool posture defining drive surface for the blade component
  • FIG. 7 is a view for describing a curvature direction of the tool posture defining drive surface shown in FIG. 6 and a workpiece machining method
  • FIG. 8 is a view for describing another embodiment of the method for creating a tool posture defining drive surface for the blade component
  • FIG. 9 is a view showing another embodiment of the tool posture defining drive surface for the blade component.
  • FIG. 10 is a view for describing the curvature direction of the tool posture defining drive surface shown in FIG. 9 ;
  • FIG. 11 is a view for describing still another embodiment of the method for creating a tool posture defining drive surface for the blade component
  • FIG. 12 is a view for describing a typical workpiece machining method.
  • FIG. 13 is a view for describing the typical workpiece machining method.
  • a blade component 1 is formed in such a manner that an unnecessary portion is removed from a rectangular parallelepiped workpiece W by a tool (not shown in FIG. 1 ) of a machine tool.
  • the blade component 1 has blade surfaces 11 formed as front and back curved surfaces with respect to a pair of edge portions 1 a , 1 b of trailing and leading edges arranged at both end portions in a width direction.
  • one blade surface 11 is a convex surface 11 a
  • the other blade surface 11 is a concave surface 11 b .
  • the blade component 1 is, for example, a turbine or compressor blade.
  • the machine tool 2 includes, on a base 21 placed on a floor, an X-axis table 22 that linearly moves in an X-axis direction and a Y-axis table 23 that linearly moves in a Y-axis direction perpendicular to the X-axis direction.
  • a rotary table 24 is mounted on an upper surface of the X-axis table 22 .
  • the rotary table 24 rotatably supports a rotation axis 25 .
  • the rotation axis 25 is member that holds the workpiece W, and rotates the held workpiece W about a C-axis.
  • the workpiece W is attached to the rotation axis 25 such that a longitudinal axis direction of the machined blade component 1 is parallel with the direction of the C-axis.
  • the rotary table 24 rotates (inclines) the rotation axis 25 itself about an A-axis.
  • the A-axis of the rotary table 24 is arranged parallel with the X-axis direction.
  • the C-axis of the rotation axis 25 is arranged on a plane perpendicular to the X-axis direction.
  • the A-axis of the rotary table 24 serves as an inclination axis about which the C-axis of the rotation axis 25 is inclined along the plane perpendicular to the A-axis.
  • a column 26 stands on an upper surface of the base 21 .
  • a main axis unit 27 that can move up and down along a Z-axis direction perpendicular to the X-axis direction and the Y-axis direction is provided at an upper end portion of the column 26 .
  • the tool T is attached to a lower end portion of the main axis unit 27 .
  • the tool T machines, by removal machining, the blade component 1 from the workpiece W rotating about the C-axis by operation of the rotation axis 25 based on a predetermined machining program.
  • a ball end mill, a tapered ball end mill, or a radius end mill is used as the tool T.
  • FIG. 4 shows one embodiment of a control device 3 of the machine tool 2 .
  • the control device 3 has a tool posture defining drive surface creation unit 31 that creates a drive surface for defining a tool posture and a machining program creation unit 32 that creates the machining program based on the tool posture defining drive surface (hereinafter merely referred to as a drive surface) created by the tool posture defining drive surface creation unit 31 .
  • FIG. 5 shows a drive surface creation method in the tool posture defining drive surface creation unit 31 .
  • the blade component 1 is shown in a section perpendicular to the longitudinal axis direction (a direction perpendicular to the plane of paper of FIG. 5 ) of the blade component 1 .
  • the tool posture defining drive surface creation unit 31 sets a machining target to a solid body of the blade component 1 , and as shown in FIG. 5 , sets a virtual convex curve 101 formed as an arc or a spline curve for the concave surface 11 b of the blade component 1 having the convex surface 11 a and the concave surface 11 b.
  • the virtual convex curve 101 is a curve set along the outer circumference of the sectional shape perpendicular to the longitudinal axis direction of the blade component 1 . Specifically, the virtual convex curve 101 is set so as to protrude outward of the blade component 1 along the outer circumference of the sectional shape perpendicular to the longitudinal axis direction of the blade component 1 with reference to tangents to minute curves of the pair of edge portions 1 a , 1 b of the blade component 1 . Thus, the virtual convex curve 101 is a curve whose curvature is not inverted from that of the convex surface 11 a.
  • four convex curves including the virtual convex curve 101 set for the concave surface 11 b , a convex curve 102 set by the convex surface 11 a , and convex curves 103 , 104 set by surfaces of the pair of edge portions 1 a , 1 b are set at the outer circumference of the blade component 1 as shown in FIG. 5 .
  • the curvature is not inverted among these four convex curves.
  • the tool posture defining drive surface creation unit 31 sets these four convex curves (the virtual convex curve 101 for the concave surface 11 b , the convex curve 102 for the convex surface 11 a , the convex curves 103 , 104 for the edge portions 1 a , 1 b ), and thereafter, creates the drive surface 200 for defining the tool posture by means of these four convex curves as shown in FIG. 6 .
  • the machining program creation unit 32 creates, as shown in FIG. 7 , the machining program for setting a tool axis direction Ta with reference to the direction of normal to the drive surface 200 created in the tool posture defining drive surface creation unit 31 .
  • the tool axis direction Ta shown in FIG. 7 is arranged along the direction of normal to the drive surface 200 .
  • the curvature directions of the four convex curves (the virtual convex curve 101 for the concave surface 11 b , the convex curve 102 for the convex surface 11 a , the convex curves 103 , 104 for the edge portions 1 a , 1 b ) set in the tool posture defining drive surface creation unit 31 are all the same as each other, the posture of the tool T determined based on the tool axis direction Ta does not change on any of the convex curves of the drive surface 200 to such an extent that the direction of operation of the rotation axis 25 needs to be reversed.
  • the machine tool 2 determines the tool posture based on the machining program created by the machining program creation unit 32 , and as shown in FIG. 7 , machines the blade component 1 from the workpiece W by removal machining by the tool T in a state in which the tool posture is maintained.
  • the tool axis direction Ta with respect to the concave surface 11 b at this point is set based on the drive surface 200 created using the virtual convex curve 101 , and therefore, the direction of operation of the rotation axis 25 is not reversed from that of the convex surface 11 a upon removal machining for the concave surface 11 b .
  • the convex curve 102 of the drive surface 200 set for the convex surface 11 a of the blade component 1 is generally connected to the convex curves 103 , 104 set for the edge portions 1 a , 1 b without changing the curvature direction in many cases.
  • the convex curve 102 set for the convex surface 11 a includes an error upon model conversion by means of computer aided design (CAD)/computer aided manufacturing (CAM) in some cases.
  • CAD computer aided design
  • CAM computer aided manufacturing
  • the tool posture defining drive surface creation unit 31 may also create, for the convex surface 11 a , a drive surface 201 with a virtual convex curve 105 as in the concave surface 11 b , the virtual convex curve 105 being formed as an arc or a spline curve with reference to the tangents to the minute curves of the edge portions 1 a , 1 b .
  • FIGS. 8 and 9 also show the blade component 1 in the section perpendicular to the longitudinal axis direction (a direction perpendicular to the plane of paper of FIGS. 8 and 9 ) of the blade component 1 .
  • the virtual convex curve 105 set for the convex surface 11 a forms a convex curve protruding outward of the blade component 1 with respect to the convex surface 11 a designed for the blade component 1 and formed smoothly continuously to the minute curves of the edge portions 1 a , 1 b .
  • the shape of the blade component 1 is such a shape that the direction of operation of the rotation axis 25 needs to be reversed upon removal machining of the convex surface 11 a , the direction of operation of the rotation axis 25 does not need to be reversed.
  • the tool posture defining drive surface creation unit 31 may create the drive surface 200 or the drive surface 201 based on a convex curve with reference to tangents to the convex curve 102 or the virtual convex curve 105 set for the convex surface 11 a and the virtual convex curve 101 set for the concave surface 11 b.
  • the tool posture defining drive surface creation unit 31 may connect, as shown in FIG. 11 , all convex curves set for the blade component 1 , i.e., the virtual convex curve 101 set for the concave surface 11 b , the virtual convex curve 105 set for the convex surface 11 a , and the convex curves 102 , 103 set for the edge portions 1 a , 1 b , thereby creating a drive surface 202 having a single smoothly-continuous spline curve.
  • This can generate a curve defining a tool axis change with a constant pitch, reduce a rapid change in the tool posture, and improve a machined surface quality.
  • the above-described tool posture defining drive surface creation unit 31 creates the drive surface 200 , 201 , 202 based on the curves of the convex surface 11 a and the concave surface 11 b of the blade component 1 .
  • the tool posture defining drive surface creation unit 31 may create a drive surface formed such that a convex curve is further added to the center of a convex surface or a drive surface formed using a plurality of convex surfaces generated from sections equally divided in the longitudinal axis direction of the blade component 1 . Accordingly, a machining program realizing a smoother tool axis change (operation of the rotation axis 25 ) can be created.
  • the posture of the tool T may be set in a state in which at least one of a lead angle or a tilt angle is inclined with respect to the tool axis direction Ta.
  • the lead angle is an angle between a tool traveling direction and a tool axis on a plane parallel with the tool traveling direction.
  • the tilt angle is an angle between the tool traveling direction and the tool axis on a plane perpendicular to the tool traveling direction.
  • At least one of the lead angle or the tilt angle is, for the posture of the tool T, inclined upon removal machining for the workpiece W by means of the tool T, and therefore, the tip end of the tool T at a circumferential speed of zero does not cut the surface across the entire machining surface of the workpiece W, i.e., the entire surface of the blade component 1 .
  • the machined surface quality can be further improved.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Human Computer Interaction (AREA)
  • Manufacturing & Machinery (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Milling Processes (AREA)
  • Numerical Control (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
US17/758,508 2020-01-23 2021-01-18 Machining program creation method, workpiece machining method, and machine tool control device Active US11642748B2 (en)

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JP2020008988 2020-01-23
JP2020-008988 2020-01-23
JPJP2020-008988 2020-01-23
PCT/JP2021/001482 WO2021149639A1 (ja) 2020-01-23 2021-01-18 加工プログラムの作成方法、ワーク加工方法及び工作機械の制御装置

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WO (1) WO2021149639A1 (ja)

Citations (6)

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Publication number Priority date Publication date Assignee Title
CH661678A5 (en) 1983-12-16 1987-08-14 Starrfraesmaschinen Ag Method for machining a shovel-shaped workpiece by a milling tool
JP2000263309A (ja) 1999-03-08 2000-09-26 Abb Alstom Power Schweiz Ag フライス切削法
JP2003165012A (ja) 2001-11-30 2003-06-10 Ishikawajima Harima Heavy Ind Co Ltd 薄肉部材の切削方法
DE102010060220A1 (de) 2010-10-28 2012-05-03 Gebr. Heller Maschinenfabrik Gmbh Verfahren zur Bearbeitung von Freiformflächen
JP2013103290A (ja) 2011-11-11 2013-05-30 Ihi Corp 翼面仕上げ方法及び翼部品
WO2014181418A1 (ja) 2013-05-09 2014-11-13 株式会社Ihi 翼面仕上げ方法及び翼部品

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DE2544612C3 (de) * 1974-10-14 1980-04-10 Leningradskoe Specialnoe Konstruktorskoe Bjuro Tyaschelych I Unikalnych Stankov, Leningrad (Sowjetunion) Rundfräsverfahren
EP0721389B1 (de) * 1993-09-29 1997-06-04 Siemens Aktiengesellschaft Verfahren zum fräsen eines entlang einer hauptachse gestreckten turbinenschaufelprofils
CN102649178B (zh) * 2012-05-17 2013-07-31 西安交通大学 自由曲面离心压气机叶轮五坐标整体铣高效粗加工方法

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Publication number Priority date Publication date Assignee Title
CH661678A5 (en) 1983-12-16 1987-08-14 Starrfraesmaschinen Ag Method for machining a shovel-shaped workpiece by a milling tool
JP2000263309A (ja) 1999-03-08 2000-09-26 Abb Alstom Power Schweiz Ag フライス切削法
JP2003165012A (ja) 2001-11-30 2003-06-10 Ishikawajima Harima Heavy Ind Co Ltd 薄肉部材の切削方法
DE102010060220A1 (de) 2010-10-28 2012-05-03 Gebr. Heller Maschinenfabrik Gmbh Verfahren zur Bearbeitung von Freiformflächen
JP2013103290A (ja) 2011-11-11 2013-05-30 Ihi Corp 翼面仕上げ方法及び翼部品
WO2014181418A1 (ja) 2013-05-09 2014-11-13 株式会社Ihi 翼面仕上げ方法及び翼部品
US20160052071A1 (en) * 2013-05-09 2016-02-25 Ihi Corporation Wing surface finishing method and wing component

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International Search Report issued in PCT/JP2021/001482; dated Mar. 30, 2021.

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US20230051567A1 (en) 2023-02-16
JP7029026B2 (ja) 2022-03-02
CN114929419B (zh) 2024-06-18
DE112021000679T5 (de) 2022-11-17
JPWO2021149639A1 (ja) 2021-07-29
WO2021149639A1 (ja) 2021-07-29

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